Overhauling Front Brake Caliper

Note: Use repair kit.





Take off plastic caps (1).
Unscrew guide bolts (2).

Installation:
Only clean guide screws; do not grease. Check guide bolts, replace if necessary.
Guide Bolt
Wrench Size 7 mm 30 - 35 Nm







Dismantle brake caliper and remove brake linings.
Installation: Press brake lining fully outwards and insert spring (4).


Warning: In the following work step, large forces occur at the brake caliper piston (up to more than 2800 N!). Danger of injury!





Press out piston with compressed air applied through connection bore.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.
Do not grip piston with fingers - risk of trapping!





Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.





Remove sealing ring carefully with a plastic needle.
Clean cylinder bores and parts with alcohol and dry with compressed air.
Thoroughly inspect cylinder bore, piston and flange surfaces.
Machining of cylinders and pistons is not permitted.





Installation: Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and sealing sleeve.
Install sealing cover in rear annular groove of cylinder bore.





Insert dust sleeve in front annular groove and press into annular groove over entire diameter.
Installation: Area between dust sleeve and brake caliper housing must be kept dry. It must not come into contact with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.





Support brake piston with commercially available extension and socket and press gently onto dust sleeve.
Blow on sleeve with compressed air (max. 3 bar). Sleeve jumps over brake piston.
Installation: Coat dust sleeve and brake piston with brake fluid to facilitate installation of dust sleeve.